3-sided cooling of a battery pack with dual-function cooling plates

Abstract

A dual-function, combined thermal/structural structure for simultaneously holding and cooling one or more battery cells that are stacked inside of a battery pack. The dual-function structure comprises: (1) a first cooling plate with a first plurality of parallel internal coolant channels; (2) a second cooling plate with a second plurality of parallel internal coolant channels; (3) a first structural side plate; (4) a second structural side plate; and (5) fasteners for joining the first cooling plate, the second cooling plate, the first structural side plate, and the second structural side plate together into an rectangular, box-like, cooled structure. The first and second cooling plates simultaneously structurally support and thermally cool one or more battery cells on at least two opposite sides. Additional horizontal cooling plates can be used to thermally cool and structurally support the underside of each battery cell, thereby providing a 3-sided cooling effect.

What is claimed is: 
     
         1 . A dual-function structure, comprising:
 a first cooling plate comprising a first plurality of internal coolant channels;   a second cooling plate comprising a second plurality of internal coolant channels;   a first structural side plate that is structurally attached to both the first and second cooling plates at proximal ends of the first and second cooling plates; and   a second structural side plate that is structurally attached to both the first and second cooling plates at distal ends of the first and second cooling plates;   wherein the first cooling plate simultaneously thermally cools and structurally supports a first side of a battery cell;   wherein the second cooling plate simultaneously thermally cools and structurally supports a second side of the battery cell; and   wherein the first side of the battery cell is located opposite to the second side of the battery cell.   
     
     
         2 . The dual-function structure of  claim 1 , further comprising:
 a battery cell disposed inside of the dual-function structure, the battery cell comprising a front side and an opposing back side;   a first layer of a Thermal Interface Material (TIM) that is disposed in between the first cooling plate and the front side of the battery cell; and   a second layer of a Thermal Interface Material (TIM) that is disposed in between the second cooling plate and the back side of the battery cell.   
     
     
         3 . The dual-function structure of  claim 1 ,
 wherein the first structural side plate is oriented at 90 degrees to the first cooling plate;   wherein the second structural side plate is oriented at 90 degrees to the second cooling plate; and   wherein the first structural side plate is oriented parallel to the second structural side plate.   
     
     
         4 . The dual-function structure of  claim 1 , further comprising:
 a first horizontal support beam; and   a second horizontal support beam, which is oriented parallel to the first horizontal support beam,   wherein the first horizontal support beam is simultaneously thermally connected and structurally attached to a first bottom side of the first cooling plate;   wherein the second horizontal support beam is simultaneously thermally connected and structurally attached to a second bottom side of the second cooling plate; and   wherein the first and second horizontal support beams structurally support and thermally cool a battery cell on a third, bottom side of the battery cell.   
     
     
         5 . The dual-function structure of  claim 4 , further comprising:
 a first combined thermal/structural joint made between the first cooling plate and the first horizontal support beam;   a second combined thermal/structural joint made between the second cooling plate and the second horizontal support beam;   a first layer of Thermal Interface Material (TIM) disposed inside the first combined thermal/structural joint; and   a second layer of Thermal Interface Material (TIM) disposed inside the second combined thermal/structural joint.   
     
     
         6 . The dual-function structure of  claim 4 ,
 wherein the first structural side plate is structurally attached to both the first horizontal support beam and the second horizontal support beam; and   wherein the second structural side plate is structurally attached to both the first horizontal support beam and the second horizontal support beam.   
     
     
         7 . The dual-function structure of  claim 1 ,
 Wherein the first and second cooling plates are made of an extruded aluminum alloy;   wherein the first plurality of internal cooling channels is oriented parallel to each other;   wherein the second plurality of internal cooling channels is oriented parallel to each other; and   wherein the first and second plurality of internal cooling channels have a rectangular cross-sectional shape.   
     
     
         8 . The dual-function structure of  claim 1 , further comprising:
 a first integral horizontal channel disposed on a top portion of the first cooling plate; and   a second integral horizontal channel disposed on a top portion of the second cooling plate;   wherein the first integral horizontal channel comprises a first recessed horizontal groove configured to hold a first vertical fastener;   wherein the second integral horizontal channel comprises a second recessed horizontal groove configured to hold a second vertical fastener;   wherein the first integral horizontal channel is open at both ends of the first integral horizontal channel; and   wherein the second integral horizontal channel is open at both ends of the second integral horizontal channel.   
     
     
         9 . The dual-function structure of  claim 4 , further comprising:
 a battery cell disposed inside of the dual-function structure, wherein the battery cell comprises a bottom side;   a third layer of a Thermal Interface Material (TIM) that is disposed in between the bottom side of the battery cell and the first horizontal support beam; and   a fourth layer of a Thermal Interface Material (TIM) that is disposed in between the bottom side of the battery cell and the second horizontal support beam.   
     
     
         10 . The dual-function structure of  claim 9 , further comprising:
 a first slidable vertical fastener disposed inside of the first recessed horizontal groove; and   a second slidable vertical fastener disposed inside of the second recessed horizontal groove.   
     
     
         11 . The dual-function structure of  claim 1 , further comprising:
 a first coolant manifold that is fluidically coupled to a distal end of the first cooling plate; and   a second coolant manifold that is fluidically coupled to a distal end of the second cooling plate;   wherein the first cooling plate and the first coolant manifold are configured so that coolant initially flows horizontally inside a lower portion of the first cooling plate's internal flow channels towards the first coolant manifold, then turns and flows vertically upwards inside the first coolant manifold, at which point the coolant flow reverses direction and flows horizontally away from first coolant manifold along an upper portion of the first cooling plate towards a first coolant exit; and   wherein the second cooling plate and the second coolant manifold are configured so that coolant initially flows horizontally inside a lower portion of the second cooling plate's internal flow channels towards the second coolant manifold, then turns and flows vertically upwards inside the second coolant manifold, at which point the coolant flow reverses direction and flows horizontally away from second coolant manifold along an upper portion of the second cooling plate towards a second coolant exit.   
     
     
         12 . A dual-function structure, comprising:
 a first cooling plate comprising a first plurality of internal coolant channels;   a second cooling plate comprising a second plurality of internal coolant channels;   a first structural side plate that is structurally attached to both the first and second cooling plates at proximal ends of the first and second cooling plates;   a second structural side plate that is structurally attached to both the first and second cooling plates at distal ends of the first and second cooling plates;   a plurality of fasteners that structurally join the first cooling plate, the second cooling plate, the first structural side plate, and the second structural side plate together into a rectangular, box-like structure; and   a battery cell;   wherein the first cooling plate simultaneously thermally cools and structurally supports a first side of the battery cell;   wherein the second cooling plate simultaneously thermally cools and structurally supports a second side of the battery cell;   wherein the first side of the battery cell is located opposite to the second side of the battery cell;   wherein the battery cell is disposed inside of a rectangular opening in the dual-function structure that is defined on four sides by: (1) the first cooling plate, (2) the first structural side plate, (3) the second cooling plate, and (4) the second structural side plate; and   wherein the dual-function structure is attached to a bottom support plate that is disposed underneath a battery pack.   
     
     
         13 . The dual-function structure of  claim 12 , further comprising:
 a first horizontal support beam,   a second horizontal support beam, which is oriented parallel to the first horizontal support beam;   wherein the first horizontal support beam is simultaneously thermally connected and structurally attached to a first bottom side of the first cooling plate; and   wherein the second horizontal support beam is simultaneously thermally connected and structurally attached to a second bottom side of the second cooling plate;   wherein the first horizontal support beam thermally cools and structurally supports the battery cell on a first portion of a first bottom side of the battery cell; and   wherein the second horizontal support beam thermally cools and structurally supports the battery cell on a second portion of a second bottom side of the battery cell;   thereby providing simultaneous three-sided structural support and three-sided thermal cooling of the battery cell.   
     
     
         14 . The dual-function structure of  claim 13 , further comprising:
 a first combined thermal/structural joint made between the first cooling plate and the first horizontal support beam;   a second combined thermal/structural joint made between the second cooling plate and the second horizontal support beam;   a first layer of Thermal Interface Material (TIM) that is disposed inside the first combined thermal/structural joint; and   a second layer of Thermal Interface Material (TIM) that is disposed inside the second combined thermal/structural joint.   
     
     
         15 . The dual-function structure of  claim 13 ,
 wherein the first structural side plate is structurally attached to both the first horizontal support beam and the second horizontal support beam; and   wherein the second structural side plate is structurally attached to both the first horizontal support beam and the second horizontal support beam.   
     
     
         16 . The dual-function structure of  claim 12 ,
 wherein the first and second cooling plates are made of an extruded aluminum alloy;   wherein the first plurality of internal cooling channels is oriented parallel to each other;   wherein the second plurality of internal cooling channels is oriented parallel to each other; and   wherein the first and second plurality of internal cooling channels have a rectangular cross-sectional shape.   
     
     
         17 . A dual-function structure, comprising:
 a first cooling plate comprising a first plurality of internal coolant channels;   a second cooling plate comprising a second plurality of internal coolant channels;   a first structural side plate that is structurally attached to both the first and second cooling plates at proximal ends of the first and second cooling plates;   a second structural side plate that is structurally attached to both the first and second cooling plates at distal ends of the first and second cooling plates;   a plurality of fasteners that structurally join the first cooling plate, the second cooling plate, the first structural side plate, and the second structural side plate together into a rectangular, box-like structure;   a first horizontal support beam;   a second horizontal support beam, which is oriented parallel to the first horizontal support beam; and   a battery cell that is disposed inside of a rectangular open cavity in the dual-function structure;   wherein the first cooling plate simultaneously thermally cools and structurally supports the battery cell on a first side of the battery cell;   wherein the second cooling plate simultaneously thermally cools and structurally supports the battery cell on a second side of the battery cell;   wherein the first side of the battery cell is located opposite to the second side of the battery cell;   wherein the first horizontal support beam is simultaneously thermally connected and structurally attached to a first bottom side of the first cooling plate;   wherein the second horizontal support beam is simultaneously thermally connected and structurally attached to a second bottom side of the second cooling plate;   wherein the first and second horizontal support beams simultaneously structurally support and thermally cool the battery cell on a third, bottom side of the battery cell;   wherein the first structural side plate is oriented at 90 degrees to the first cooling plate;   wherein the second structural side plate is oriented at 90 degrees to the second cooling plate;   wherein the first structural side plate is oriented parallel to the second structural side plate;   wherein the first structural side plate is structurally attached to proximal ends of both the first horizontal support beam and the second horizontal support beam;   wherein the first structural side plate is attached to proximal ends of both the first horizontal support beam and the second horizontal support beam;   wherein the second structural side plate is attached to distal ends of both the first horizontal support beam and the second horizontal support beam;   wherein the first horizontal support beam thermally cools the battery cell on a first portion of a bottom side of the battery cell; and   wherein the second horizontal support beam thermally cools the battery cell on a second portion of a bottom side of the battery cell;   thereby providing simultaneous three-sided structural support and thermal cooling of the battery cell.   
     
     
         18 . The dual-function structure of  claim 17 , wherein the battery cell is disposed in a rectangular open cavity in the dual-function structure that is defined on four sides by: (1) the first cooling plate, (2) the first structural side plate, (3) the second cooling plate, and (4) the second structural side plate. 
     
     
         19 . The dual-function structure of  claim 17 , further comprising:
 a first combined thermal/structural joint made between the first cooling plate and the first horizontal support beam;   a second combined thermal/structural joint made between the second cooling plate and the second horizontal support beam;   a first layer of Thermal Interface Material (TIM) that is disposed inside the first combined thermal/structural joint; and   a second layer of Thermal Interface Material (TIM) that is disposed inside the second combined thermal/structural joint.   
     
     
         20 . The dual-function structure of  claim 17 , further comprising:
 a first integral horizontal channel disposed on a first top portion of the first cooling plate;   a second integral horizontal channel disposed on a second top portion of the second cooling plate;   a first horizontal recessed groove disposed in the first integral horizontal channel, for holding a first vertical fastener; and   a second horizontal recessed groove disposed in the second integral horizontal channel, for holding a second vertical fastener;   a first slidable vertical fastener that is disposed in the first horizontal recessed groove;   a second slidable vertical fastener that is disposed in the second horizontal recessed groove; and   a hollow structural channel that is structurally attached to both the first and the second slidable vertical fasteners;   wherein the hollow structural channel is disposed on a top portion of both the first cooling plate and the second cooling plates;   wherein the hollow structural channel is oriented at 90 degrees to both the first cooling plate and the second cooling plate;   wherein the first integral horizontal channel is open at proximal and distal ends of the first integral horizontal channel; and   wherein the second integral horizontal channel is open at proximal and distal ends of the second integral horizontal channel.